Method and system for imaging and modeling dental structures

ABSTRACT

Systems and methods optically image a dental structure within an oral cavity by: directing air at a tooth-gum interface of the dental structure through at least one air nozzle movably coupled to an intra-oral track; coating the dental structure with a substance to enhance the image quality; and capturing one or more images of the dental structure through at least one image aperture, the image aperture movably coupled to the intra-oral track.

FIELD OF INVENTION

[0001] The present invention relates to intra-oral methods and apparatusfor optically imaging a dental structure and creating representative 3Dmodels from the images.

BACKGROUND

[0002] In many dental applications, a working model of a patient's teethis needed that faithfully reproduces the patient's teeth and otherdental structures, including the jaw structure. Conventionally, athree-dimensional negative model of the teeth and other dentalstructures is created during an impression-taking session where one ormore U-shaped trays are filled with a dental impression material.Impression materials include, among others, compositions based onalginates, polysulphides, silicones and vulcanizable polyethermaterials. The impression material is typically prepared by mixing abase component and a hardener or initiator or catalyst component. Theimpression tray containing the impression material, in its plasticstate, is introduced into the mouth of the patient. To ensure a completeimpression, an excessive amount of impression material is typicallyused. While the tray and impression material is held in place, thematerial cures, and after curing, the tray and material are removed fromthe mouth as a unit. The impression material is allowed to solidify andform an elastic composition, which is the negative mold after removal.The working model is obtained by filling this impression with a modelingmaterial.

[0003] Dental patients typically experience discomfort when the dentisttakes an impression of the patient's teeth. The procedure can be evenmore uncomfortable for the patient if the impression materials run,slump or are otherwise expelled into the patient's throat. Suchsituations can potentially cause a gag reflex reaction from the patient.In addition to patient discomfort, the impression process is timeconsuming. Additionally, the impression process can be error-prone. Forexample, when the impression material is not properly applied, theresulting working model may not accurately reflect features on theteeth. Moreover, the model can show air bubbles trapped during theimpression taking session. Depending on the accuracy required, suchworking model may not be usable and additional dental impressions mayneed to be taken. Further, the mold and working model are fragile andcan be easily damaged. The need to store the fragile models for futurereference tends to become a logistical problem for a dental practice asthe number of archived models accumulates.

[0004] Automated scanning techniques have been developed as alternativesto the mold casting procedure. Because these techniques can create adigital representation of the teeth, they provide the advantage ofcreating an “impression” that is immediately transmittable from thepatient to a dental laboratory. The digital transmission potentiallydiminishes inconvenience for the patient and eliminates the risk ofdamage to the mold. For example, U.S. Pat. No. 6,050,821 discloses amethod and apparatus for intra-orally mapping the structure andtopography of dental formations such as peridontium and teeth, bothintact and prepared, for diagnosis and dental prosthetics and bridgeworkby using an ultrasonic scanning technique. As claimed therein, themethod can provide details of orally situated dental formations thusenabling diagnosis and the preparation of precision moldings andfabrications that will provide greater comfort and longer wear to thedental patient. Also, as discussed therein, infra-red CAD/CAM techniqueshave been used to map impressions of oral structures and makesingle-tooth prosthetics.

[0005] Also, in certain applications such as restorative dentistry thatis preformed on visible teeth, such as incisors, aestheticconsiderations require that the prosthetic interface with the originaltooth surface be underneath the gum (sub gingival) to eliminate thesight of the “joining line”. In preparation for the prosthetic, thepatient's tooth must be shaped to create a ledge or margin beneath thegum line where the prosthetic will be sealed to the existing tooth. Toprepare this surface, the dentist typically places a retraction cordbetween the tooth and gum. The retraction cord creates a working spacethat allows the dentist to machine the margin around the tooth ofinterest.

[0006] In order for the finished prosthetic to be correctly sized andproperly seated on the prepared tooth, it is essential that theimpression of the prepared tooth contain an accurate representation ofthe sub gingival margin. Improper resolution of the margin in theimpression and the subsequent creation of the prosthetic from thisimpression can result in a poor seal along the margin of the preparedtooth and the prosthetic. A poor seal along the margin has the potentialto expose the underlying tooth to decay and the subsequent loss of thetooth—the very thing the prosthetic was suppose to prevent. Two methodsare commonly used to accurately capture the margin during the impressionprocess. The first method uses a retraction cord to hold the gum awayfrom the tooth surface to allow the impression compound to flowunderneath into the sub gingival region. The second method uses animpression material with low viscosity that under pressure is forcedunderneath the gums and thus captures the sub gingival margin.

[0007] In addition to obtaining sub gingival access for the impressionmaterial, the area of interest should be dry and clean (dry field) toobtain an accurate impression. A dry field is needed because typicalimpression compounds are hydrophobic and the presence of moisture whenusing a hydrophobic impression compound results in bubbles in theimpression. The dry field is typically created by the dentist directingpressurized air across the prepared surface just prior to placing theimpression tray in the patient's mouth.

SUMMARY

[0008] In one aspect, a method optically images a dental structurewithin an oral cavity by: directing air at a tooth-gum interface of thedental structure through at least one air nozzle movably coupled to anintra-oral track; and capturing one or more images of the dentalstructure through at least one image aperture, the image aperturemovably coupled to the intra-oral track.

[0009] Implementations of the above aspect may include one or more ofthe following. The air nozzle can be moved incrementally or continuouslywithin the oral cavity. A motor may move the air nozzle incrementally orcontinuously within the oral cavity. The dental structure can be coatedwith a substance to enhance the image quality. An illuminator movablymounted on the intra-oral track can illuminate the dental structure. Theilluminator can be moved incrementally or continuously within the oralcavity. A three-dimensional (3D) model of the dental structure can begenerated based on the images captured by the image aperture. Astereometric analysis can be performed on the captured images. Themethod includes performing a scanning illumination beam andtriangulation analysis on the captured images. The 3D model may betransmitted over a network. Diagnosis and treatment of a patient can bedone with the 3D model.

[0010] In another aspect, a system to optically image a dental structurewithin an oral cavity includes: an intra-oral track adapted to beinserted inside the oral cavity; a pressurized air nozzle moveablycoupled to the track to direct air at the dental structure; and at leastone image aperture movably coupled to the intra-oral track and adaptedto capture one or more images of the dental structure.

[0011] Implementations of the above aspect may include one or more ofthe following. The image aperture is either incrementally orcontinuously moved on the track. A motor coupled to the image aperturecan move the image aperture incrementally or continuously within theoral cavity. The intra-oral track can be arch-shaped. One or moreilluminators movably mounted on the intra-oral track can illuminate thedental structure. Each illuminator is incrementally or continuouslymoved within the oral cavity. An image processor can perform astereometric analysis on the captured images to generate athree-dimensional model. The image processor can scan an illuminationbeam and perform triangulation analysis on the captured images togenerate a three-dimensional model. A display can be coupled to theimage processor to show a representation of the 3D model. The imageprocessor can be coupled to a network to transmit the 3D model to aremote system. A camera can be connected to the image aperture, and canbe intra-orally mounted or can be mounted outside of the oral cavity.

[0012] In another aspect, a system to optically image a dental structurewithin an oral cavity includes an intra-oral track adapted to beinserted inside the oral cavity; a spray orifice moveably coupled to thetrack to coat the dental structure with a material; and at least oneimage aperture movably coupled to the intra-oral track and adapted tocapture one or more images of the dental structure.

[0013] In yet another aspect, a system to optically image a dentalstructure within an oral cavity includes an intra-oral track adapted tobe inserted inside the oral cavity; a pressurized air nozzle moveablycoupled to the track to direct air at the dental structure; a sprayorifice moveably coupled to the track to coat the dental structure witha material; and at least one image aperture movably coupled to theintra-oral track and adapted to capture one or more images of the dentalstructure.

[0014] In still another aspect, a method for optically imaging a dentalstructure within an oral cavity includes coating the dental structurewith a substance to enhance the image quality; and capturing one or moreimages of the dental structure through at least one image aperture, theimage aperture movably coupled to the intra-oral track.

[0015] In another aspect, a method for optically imaging a dentalstructure within an oral cavity includes directing air at a tooth-guminterface of the dental structure through at least one air nozzlemovably coupled to an intra-oral track; coating the dental structurewith a substance to enhance the image quality; and capturing one or moreimages of the dental structure through at least one image aperture, theimage aperture movably coupled to the intra-oral track.

[0016] Advantages of the system may include one or more of thefollowing. The system rapidly takes intra oral images of dry field subgingival dental structures. The system also provides a spray orifice tocoat dental structure with substance to improve the imaging capability.Images of the dental structures are captured with sufficient resolutionsuch that the acquired images can be processed into accurate 3D modelsof the imaged dental structures. The images and models would haveapplication in dental diagnosis and for the specification andmanufacture of dental prosthetics such as bridgeworks, crowns or otherprecision moldings and fabrications.

[0017] Further, the system provides automated intra-oral scanning of allthe dental structures in the jaw through an optical aperture andcombines the information available in the entire set of images to createand present an accurate 3D model of the scanned structures. The systemallows intra-oral images of dental structures to be taken rapidly andwith high resolution such that the acquired images can be processed intoaccurate 3D models of the imaged dental structures. The images andmodels can be used in dental diagnosis and used for the specificationand manufacture of dental prosthetics such as bridgeworks, crowns orother precision moldings and fabrications. In addition, the systemproduces 3D models useful in the diagnosis and treatment planningprocess for dental malocclusions. The system-produced data representinga set of dental images and models can be transmitted electronically tosupport activity such as professional consultations or insuranceprovider reviews, and the images and models may be electronicallyarchived for future reference.

[0018] The digital 3D model of patient's teeth and other dentalstructures has advantages over a conventional cast physical model due tothe following: 1) 3D model efficiently created in a single step withaccuracy meeting or exceeding the conventional multiple step impressiontechnique; 2) reduced storage costs; 3) immediate, labor-free retrievaland archiving; 4) no model breakage; 5) integrates directly intocomputer based analysis tools for diagnosis and treatment planning; 6)digital models backup; 7) e-mails to colleagues, dental specialists,insurance companies; 8) access to information from home, satelliteoffice; 9) effective presentation tool; 10) no mess and dust; and 11) nowasted staff time.

[0019] The above and other features and advantages of the presentinvention will be apparent in the following detailed description of thepreferred embodiments of the present invention when read in conjunctionwith the accompanying drawings in which corresponding parts areidentified by the same reference symbol.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020]FIG. 1 illustrates an embodiment of a system for performingintra-oral scanning and for generating 3D models of teeth and otherdental structures.

[0021]FIG. 2 shows an exemplary embodiment of a scanner with oneaperture.

[0022]FIG. 3 shows a second embodiment of a scanner with a plurality ofapertures.

[0023]FIG. 4 illustrates a process in capturing images and generating 3Dmodels from a patient.

[0024]FIG. 5 shows an exemplary image processor for generating 3Dmodels.

[0025]FIG. 6 shows an exemplary embodiment for modeling surface locationand contour from stereo images.

[0026]FIG. 7 shows an exemplary computer for using the 3D models.

[0027]FIG. 8 shows a third exemplary embodiment of a scanner with oneaperture, air nozzle and spray orifice.

[0028]FIG. 9 shows a fourth embodiment of a scanner with a plurality ofapertures, air nozzles and spray orifices.

[0029]FIG. 10 illustrates a process utilizing air jets and sprayorifices while capturing images and generating 3D models from a patient.

[0030]FIG. 11 shows an exemplary image processor for generating 3Dmodels with controls for air jets and spray orifices.

DESCRIPTION

[0031] Referring to FIG. 1, a system block diagram depicting theinstrumentation used in scanning teeth and other dental structure imagesand in generating 3D models, will facilitate a general understanding andappreciation of the disclosed method and apparatus.

[0032] In FIG. 1, an intra-oral scanner 100 is adapted to be placedinside the mouth of the patient (intra-oral cavity). The intra-oralscanner 100 captures images of various dental structures in the mouthand communicates this information with a remote image processor 110. Theremote image processor 110 in turn can communicate with a computer 120and can display images of the dental structures on a display 122connected to the computer 120. Alternatively, functionalities of thecomputer 120 such as data storage and display can be provided directlyby the remote image processor 110 in another embodiment. Images and 3Dmodels derived from the images can be transmitted as digital files toother equipment or locations by the computer 120.

[0033] In one implementation, the intra-oral scanner 100 is embedded inan intra-oral structure, such as a mouthpiece 130. An image aperture 132is provided to capture images of the dental structures. The imageaperture 132 can be an objective lens followed by relay lens in the formof a light-transmission cable such as a fiber optic cable to transmitimages of the dental structures along a pre-selected distance to acamera. The fiber optic cable transmits light through small filamentaryoptical materials or fibers. Typically, the fibers include a centralcore and an outer surrounding cladding along the entire length of thefiber. The transmission of light through the fiber is based on thephenomenon of total internal reflection. For total internal reflection,the refractive index of the core is greater than the refractive index ofthe cladding. In one embodiment, optical fibers for the transmission ofimages comprised of visible through mid-infrared light can be used.

[0034] The output of the image aperture 132 can be provided to one ormore sensors for detecting and converting incident light (photons fromthe light source reflected off the dental structure surface)—first intoelectronic charge (electrons) and, ultimately into digital bits. In oneimplementation, the output of the image aperture 132 is provided to acamera (not shown), which can be analog or digital. In one embodiment,the camera contains one or more image sensor(s) used to create digitalimages of the dental structure. These sensors can be devices such as acharge-coupled device (CCD) sensor or a complementary metal oxidesemiconductor (CMOS) image sensor. The image sensor can be an array ofindividual photosensitive cells (pixels) whose size determines thelimiting resolution. Image sensor arrays can have from 16×16 pixels tomore than 1024×1024 pixels, and the arrays can be symmetrical orasymmetrical.

[0035] Further, a source of light delivered through an illuminator 134is provided to illuminate the dental structures to improve the qualityor contrast of the images taken by the image aperture 132. The light canbe white light, light shown in one or more colors, or can come from alaser beam. The intensity of the light source used to illuminate thedental structure is ideally controllable and is in the frequency rangeof visible or infra-red light. In one embodiment, the light source canbe integral to the mouthpiece 130. In another embodiment, light can berouted from the light source to the illuminator 134 by one or more fiberoptic cables (not shown). This bundle of optical fibers can bepositioned to surround the outer circumference of the image aperture 132to create a plurality of illuminators. The field of illumination may begreater than the field of view of the image aperture 132 and may rangeup to 180 degrees. In another embodiment, the field of illumination maybe a focused beam that illuminates a spot on the dental structure withan illumination spot size of dimensions less than 5 mm.

[0036] A drive mechanism 136 is provided to incrementally orcontinuously move the image aperture 132 and the illuminator 134 tovarious positions in the intra-oral cavity. In one embodiment, the imageaperture 132 and the illuminator 134 are movably mounted on a track thatis driven by the drive mechanism 136. The track can be a U-shaped trackconforming to the shape of the patient's arch. The drive mechanism 136can be electrically actuated to move the image aperture 132 and theilluminator 134 around all teeth and other structures in the jaw. Any ofa variety of drive motors can be used, and the power of the motorthrough the drive mechanism 136 can be translated into motion for theimage aperture 132 and the illuminator 134 through rotary, linear,hydraulic, or pneumatic mechanisms for example.

[0037] The intra-oral apparatus, as exemplified by mouthpiece 130,provides the mechanism for traversing image aperture 132 and theilluminator 134 around the oral cavity and positioning the imagegathering aperture(s) 132A and illuminator(s) 134 at known positionswhile taking images of the dental structures. The mouthpiece 130 in oneembodiment includes a sensor arc track 210 that allows the imageaperture to traverse an arc to capture the image of the dental structurewhile also moving laterally (FIG. 2). In another embodiment, themouthpiece 130 supports multiple image gathering apertures in knownmechanical alignment and moving of said apertures laterally around theoral cavity (FIG. 3).

[0038] Although the scanning of one jaw arch at a time has beendescribed, it is to be understood that two mouthpieces can besimultaneously deployed to capture images of dental structures on boththe upper and lower jaw arches.

[0039]FIG. 2 shows one embodiment of the mouthpiece having a singleimage aperture. In the embodiment of FIG. 2, the mouthpiece 130 has abase 200 that is shaped substantially in an arch-shape or U-shape.Mounted on the base 200 is a lateral rail or track 202 that alsoconforms to the arch shape or U-shape. The track 202 supports a movableshuttle 204 driven by the drive mechanism 136. The shuttle 204 has anupwardly extending arm 206. Resting on top of the arm 206 are the imageaperture 132 and the illuminator 134 of FIG. 1. Additionally, the arctrack 210 allows the arm 206 to move from a frontal to a posterior viewof the teeth. At each lateral position, the image aperture 132 traversesthe arc track 210 over the dental structure to collect a sufficientnumber of images on both sides of the dental structure before moving tothe next lateral position and repeating the process. The track 202 alsoincludes sensors or indicators such as scale marks located at either endof the track 202 and along the track to provide image aperturepositional feedback information. Alternatively, positional informationcan be ascertained by methods such as counting drive motor revolutionsand deducing the position based on counting motor revolutions.

[0040]FIG. 3 shows another embodiment with multiple image apertures thatrequire only lateral motion. In this embodiment a plurality of imageapertures 132A and the illuminator(s) 134A are mounted in a knownorientation to one another on a laterally moveable apparatus. The numberof image apertures and their orientation is selected to providesufficient coverage and overlap of the dental structure to be modeled atthe desired resolution. At each lateral position, an image from each ofthe apertures 132A is recorded for later processing. In eitherembodiment of FIG. 2 or FIG. 3, the image apertures 132 or 132A may besensors integral to the mouthpiece or fiber optic image bundlesconnected directly to the mouthpiece. In the latter case, the fiberoptic image bundle transmits the image to the image sensor on anexternal printed circuit board (PCB). To optimize the image collectionat the image aperture, mirrored surfaces and optical lenses may beemployed to direct and focus the image onto the image sensor.

[0041] As discussed above, the intra-oral scanner 100 containscomponents that support one or more of the following functions: 1)illuminate the dental structure to be imaged; 2) digitally image adental structure from different aspects; and 3) reposition both theillumination and imaging apertures so as to traverse the entireintraoral cavity.

[0042] The intra-oral scanner 100 can be self-powered or power can beprovided by the image processor 110. Further, the output of theintra-oral scanner 100 is received and processed by the image processor110. In one embodiment, the output of the scanner 100 includes imagestransmitted through a fiber optic cable. These images are provided to acamera that digitizes the images and stores the digital images in amemory buffer. In a second embodiment, the output of the scanner 100 isalready in digital form, and this data is stored in the memory buffer ofthe image processor 110 for processing, as described in more detailbelow.

[0043]FIG. 4 shows an exemplary process 250 for scanning and generating3D models of dental structures. First, the mouthpiece 130 is insertedinto the patient's mouth (step 252). Next, a reset operation isperformed to move the shuttle 204 to an initial known position (step254). The illuminator 134 position, light spectrum and light strength isestablished (step 255). The image processor 110 receives an imagethrough the image aperture 132 and captures the image to its memory(step 256). The image processor 110 then instructs the image aperture132 to traverse the arc track 210 over the dental structure to collect asufficient number of images on both sides of the dental structure (step258). The image processor 110 then actuates the drive mechanism 136 tomove the shuttle 204 to the next incremental lateral position (step260). At each lateral position, the image aperture 132 traverses the arctrack 210 over the dental structure to collect a sufficient number ofimages on both sides of the dental structure before moving to the nextlateral position. Next, the process 250 tests whether the shuttle 204reaches the end of the patient's arch (step 262). If not, the processloops back to step 256 to continue the image acquisition operation. Ifthe end has been reached, the process 250 generates a 3D model using thecaptured images (step 264) and displays the 3D model for review (step266).

[0044] Turning now to FIG. 5, an exemplary image processor 110 is shown.The image processor 110 includes a central processing unit (CPU) 300,which can be a high performance CISC or RISC processor. The CPU 300 isconnected to random access memory (RAM) 302 and read only memory (ROM)304. The CPU 300 also is connected to a plurality of input/outputdevices, including a display 306, a motor and iluminator input/outputport 308 to control the drive mechanism 136 and the illuminator 134(FIG. 1), an image interface 310 to receive image data from the scanner100, and a computer interface 312. The CPU 300 can also be connected toa storage drive 314 such as a hard drive to store software and data andprovides an interface for the communication of data with otherequipment.

[0045] The CPU 300 executes code to control the image data acquisitionand generate 3D models from the captured images. The captured images areprocessed with a pattern recognizer that maps various points of anobject observed in the captured images, thereby obtaining theshape/contour information. In one implementation, 2D digitized images ofthe dental structures are output from the scanner 100 and stored incomputer memory of the image processor 110 along with the positionalinformation and illuminator settings. The stored images from a pluralityof images obtained at different positions of the image aperture are thenanalyzed using stereometric methods to form a 3D view. This process isrepeated for the complete set of captured images to create a full 3Dmodel of the scanned dental structures in the oral cavity. The 3D modelis then presented on a display or used in conjunction with a CAD/CAMsystem for patient diagnosis and treatment.

[0046]FIG. 6 shows an exemplary embodiment for using stereo images tomodel the surface contour of dental structures. The example of FIG. 6 isdescribed in terms of two-dimensions, but the process is readilyextended to the third axis to derive three-dimensional surface contoursfor 3D models. With reference to FIG. 6, the following process is usedto derive the position of a specific scene element 480 observed inimages 482 and 484 captured through image apertures 486 and 488.

[0047] The image processor uses conventional image pattern matchingtechniques to identify a scene element that is observed in both image482 and image 484. Further, based upon the image aperture field of viewangle and the location of the specific scene element within the imagesensor's array of pixels, the line of sight angle between the geometricplane of the image sensor and the scene element is derived. These lineof sight angles are denoted in FIG. 6 as Q1 for an image aperturelocated at X1, Y1 and Q2 for an image aperture located at X2, Y2.

[0048] Let the as yet unknown coordinates for the location of the sceneelement of interest be denoted x_(u) and y_(u).

[0049] Based upon the geometry of the case of FIG. 6,

y _(u)=(tan Q 1·x _(u))+y ₁

[0050] and

tan Q 2=−(y _(u) −y ₂)/x _(u)

[0051] The value of x_(u) and y_(u) can now be solved using the abovetwo equations and conventional techniques applicable to sets of linearequations. The stereometric method above can be generalized to add athird dimension Z_(u) and thereby derive a 3D surface contour or modelof the imaged dental structure. The 3D version is based on differencesin the line of sight angles projected into the third dimension to adental structure element as viewed from at least two different aperturelocations.

[0052] While for illustrative purposes this description is based uponthe use of just two images, it is to be understood that the concept canbe extended to more precisely find the 3D coordinates of a scene elementby utilizing a multitude of images of the dental structure, taken from amultitude of image aperture positions and utilizing a multitude ofillumination conditions.

[0053] In another implementation, image-processing operations based ontriangulation can be used where beams of light are projected onto thedental structures and three-dimensional spatial locations are determinedfor points where the light reflects from the dental structure object. Asthe reflected light bounces off the object at an angle relative to theknown location and bearing of the light source, the system collects thereflection information from a known location relative to the lightsource and then determines the coordinates of the point or points ofreflection by triangulation. A single dot system projects a single beamof light which, when reflected, produces a single dot of reflection. Ascan line system beams a plane of light against the dental structure andwhich is reflected as a curvilinear-shaped set of points describing onecontour line of the object. The location of each point in thatcurvilinear set of points can be determined by triangulation. The systemprojects a light plane (i.e., a laser stripe) from a known location andreads the reflection of multiple points depicting the contour of thedental structure at a location distant from the camera and from whichthe position can be triangulated.

[0054] In addition to optical triangulation systems, other alternativeoptical scanning systems can be used, including range meters systems.Range meter systems typically use an infrared-pulsed laser andmechanical scanning techniques to project a dot laser across an objectand then measure the phase delay of the reflected signal.

[0055] Once the dental structure coordinates have been scanned, thesystem removes redundant points and generates a 3D model from thescanned data using various techniques known in the art. In oneembodiment, the process examines data for two adjacent laser stripes.Next, the process sweeps through each Y coordinate from the top of thetwo laser stripes to the bottom of the two stripes and creates trianglesfor the geometric 3D model. When the process has reached the bottom ofthe stripes, the triangulating process for the current laser stripes isfinished and the next set of adjacent scan lines are retrieved until atriangulated mesh covering the whole dental structure is generated. Oncethe mesh has been generated, a 3D model with realistic shading andlighting can be generated.

[0056]FIG. 7 shows an exemplary computer 500 for processing dental imagedata and for generating 3D models. The system 500 includes a processor(CPU) 512, RAM 516, ROM 518 and an I/O controller 520 coupled by a CPUbus 514. The I/O controller 520 is also coupled to an I/O bus 535. TheI/O bus 535 communicates with an I/O interface 532 that in turn controlsa solid state drive (flash RAM) 534 or a removable disk drive. The I/Obus 535 is also connected to input devices such as a touch-screendisplay 536. In place of, or in parallel with the touch-screen display536, a keypad can be connected to the I/O bus 535 to receive user dataentry. Alternatively, voice recognition can be used in conjunction withand/or replace the touch-screen display 536 or keypad. In such anembodiment, a microphone 537 is connected to an analog to digitalconverter (ADC) 538 that interfaces with the processor 512.

[0057] A network access card 540 can be connected to the I/O bus 535 toallow the computer 500 access to a network 542. Through the network 542,or through a modem 550 connected to the I/O bus 535, the computer 500can access a wide area network 560 such as the Internet. An Internetcommunity with one or more service providers or marketers is connectedto the network. The Internet community can provide value added servicessuch as services to create a physical teeth model from the 3D model.

[0058] FIGS. 8-9 shows additional embodiments providing additionalcapabilities of directing pressurized air at the dental structure thatis being imaged to 1) create a dry field; and 2) allow sub gingivalimage capture. Furthermore, these embodiments provide a spray orificefor dispensing a coating substance such as titanium dioxide onto thedental structures during the digital imaging process. The timing,duration and intensity of the directed air source and spray dispensingon the dental structure are precisely controllable. In oneimplementation, the pressurized air source is obtained by interfacingthe apparatus to an existing air source using an industry standardinterface at the patient dental chair.

[0059] One embodiment of the mouthpiece uses a single air jet 810 andspray orifice 820 (FIG. 8). At each lateral position as the imageaperture traverses an arc over the dental structure, the air jet outputis directed at the region of the dental structure currently being imagedand is synchronized with the image capture. The spray orifice is alsodirected at the dental structure being imaged but dispenses the coatingprior to image capture.

[0060] Yet another embodiment uses multiple air jets to simultaneouslydirect air at multiple regions of the dental structure in synchronismwith the capture of the dental structure images (FIG. 9). In thisembodiment a plurality of air jets 910 and 910′ are mounted in a knownorientation to one another on a laterally moveable apparatus. The numberof air jets and their orientation is selected to provide sufficientcoverage and overlap of the dental structure to be digitally imaged andmodeled. In the embodiment of FIG. 9, multiple spray orifices 920 and920′ are integrated into the mouthpiece to provide coverage of all areasthat are being imaged. In either embodiment (FIGS. 8 or 9), thepressurized air source may be integral to the mouthpiece or connecteddirectly to the mouthpiece via tubing. In the latter case, thepressurized air source is ideally an existing source located at thepatient dental chair. The mouthpiece would connect to this source usinga standard industry interface.

[0061] In one embodiment, the air nozzle receives air from an air sourcethrough a flexible hose such as a rubber hose. The air supply is passedthrough an air regulator that is in turn connected to an air solenoid toturn on and off the air at appropriate time.

[0062] A stream of air is directed at the surface of the dentalstructure using the nozzle. As the air is directed in a thin lowpressure stream onto the dental structure, the particles may bedislodged from the surface of the dental structure while the dentalstructure is dried. The air flow or stream is preferably directed at thedental structure in a substantially fan5-shaped or conical flow patternso that air strikes the structure at a range of angles up to about 45degrees with respect to the surface of the tooth. This conical flowpattern is elliptical in cross-section with a length as much as two tothree times its width.

[0063] In another embodiment for spraying materials such as whiteningingredients to the dental structure, air supplied by a compressor isdelivered to a chamber in the nozzle. The compressed air in the chambercreates suction on a material line, which runs from the chamber to atank containing the whitening material. The suction draws whiteners fromthe tank into the chamber and entrains the material with the compressedair for delivery onto the dental structure.

[0064]FIG. 10 shows an exemplary process 1250 utilizing an air nozzleand spray nozzle for scanning and generating 3D models of dentalstructures. First, the mouthpiece 130 is inserted into the patient'smouth (step 1252). Next, a reset operation is performed to move theshuttle 204 to an initial known position (step 1254). The illuminator134 position, light spectrum and light strength are established (step1256). The air nozzle 810 position and air flow characteristic areestablished (step 1258). The coating material spray nozzle 820 positionand spray parameters are established (step 1260). The image processor110 receives an image through the image aperture 132 and captures theimage to its memory (step 1262). The image processor 110 then instructsthe image aperture 132 to traverse the arc track 210 over the dentalstructure to collect a sufficient number of images on both sides of thedental structure (step 1264). The image processor 110 then actuates thedrive mechanism 136 to move the shuttle 204 to the next incrementallateral position (step 1266). At each lateral position, the imageaperture 132 traverses the arc track 210 over the dental structure tocollect a sufficient number of images on both sides of the dentalstructure before moving to the next lateral position. Next, the process1250 tests whether the shuttle 204 reaches the end of the patient's arch(step 1268). If not, the process loops back to step 1262 to continue theimage acquisition operation. If the end has been reached, the process1250 generates a 3D model using the captured images (step 1270) anddisplays the 3D model for review (step 1272).

[0065] Turning now to FIG. 11, an embodiment of an image processor 110that includes control of an air nozzle and spray nozzle is shown. Theimage processor 110 includes a central processing unit (CPU) 1300, whichcan be a high performance CISC or RISC processor. The CPU 1300 isconnected to random access memory (RAM) 1302 and read only memory (ROM)1304. The CPU 1300 also is connected to a plurality of input/outputdevices, including a display 1306, a motor and illuminator input/outputport 1308 to control the drive mechanism 136 and the illuminator 134(FIG. 1), an air nozzle I/O port 1310 to control the position andoperation of the air nozzle 810 (FIG. 8), a spray nozzle I/O port 1312to control the position and operation of the material spray nozzle 820(FIG. 8), an image interface 1314 to receive image data from the scanner100, and a computer interface 1316. The CPU 1300 can also be connectedto a storage drive 1318 such as a hard drive to store software and dataand provides an interface for the communication of data with otherequipment.

[0066] The above system supports a rapid imaging of dental structures insuch a way, and with sufficient resolution such that the acquired imagescan be processed into accurate 3D models of the imaged dentalstructures. The images and models can be processed on the computer 500to provide dental diagnosis and to support the specification andmanufacture of dental prosthetics such as bridgeworks, crowns or otherprecision moldings and fabrications. The computer 500 can transmit datarepresenting a set of dental images and models over a wide area networksuch as the Internet to support activity such as professional consultsor insurance provider reviews and the images and models may beelectronically archived for future reference.

[0067] Although an illustrative embodiment of the present invention, andvarious modifications thereof, have been described in detail herein withreference to the accompanying drawings, it is to be understood that theinvention is not limited to this precise embodiment and the describedmodifications, and that various changes and further modifications may beeffected therein by one skilled in the art without departing from thescope or spirit of the invention as defined in the appended claims.

What is claimed is:
 1. A method for optically imaging a dental structurewithin an oral cavity, comprising: a) directing air at a tooth-guminterface of the dental structure through at least one air nozzlemovably coupled to an intra-oral track; and b) capturing one or moreimages of the dental structure through at least one image aperture, theimage aperture movably coupled to the intra-oral track.
 2. The method ofclaim 1, further comprising moving the air nozzle incrementally orcontinuously within the oral cavity.
 3. The method of claim 2, furthercomprising actuating a motor to move the air nozzle incrementally orcontinuously within the oral cavity.
 4. The method of claim 1, furthercomprising coating the dental structure with a substance to enhance theimage quality.
 5. The method of claim 1, further comprising providing anilluminator movably mounted on the intra-oral track to illuminate thedental structure.
 6. The method of claim 5, further comprising movingthe illuminator incrementally or continuously within the oral cavity. 7.The method of claim 1, further comprising generating a three-dimensional(3D) model of the dental structure based on the images captured by theimage aperture.
 8. The method of claim 7, wherein generating athree-dimensional model further comprises performing a stereometricanalysis on the captured images.
 9. The method of claim 7, whereingenerating a three-dimensional model further comprises performing ascanning illumination beam and triangulation analysis on the capturedimages.
 10. The method of claim 7, further comprising transmitting the3D model over a network.
 11. The method of claim 7, further comprisingdiagnosis and treatment of a patient using the 3D model.
 12. A system tooptically image a dental structure within an oral cavity, comprising: anintra-oral track adapted to be inserted inside the oral cavity; apressurized air nozzle moveably coupled to the track to direct air atthe dental structure; and at least one image aperture movably coupled tothe intra-oral track and adapted to capture one or more images of thedental structure.
 13. The system of claim 12, wherein the image apertureis either incrementally or continuously moved on the track.
 14. Thesystem of claim 12, further comprising a motor coupled to the imageaperture to move the image aperture incrementally or continuously withinthe oral cavity.
 15. The system of claim 12, wherein the intra-oraltrack is arch-shaped.
 16. The system of claim 12, further comprising oneor more illuminators movably mounted on the intra-oral track toilluminate the dental structure.
 17. The system of claim 16, whereineach illuminator is incrementally or continuously moved within the oralcavity.
 18. The system of claim 12, further comprising an imageprocessor performing a stereometric analysis on the captured images togenerate a three-dimensional model.
 19. The system of claim 18, whereinthe image processor scans an illumination beam and performstriangulation analysis on the captured images to generate athree-dimensional model.
 20. The system of claim 18, further comprisinga display coupled to the image processor to show a representation ofsaid 3D model.
 21. The system of claim 18, wherein the image processoris coupled to a network to transmit the 3D model to a remote system. 22.The system of claim 12, further comprising a camera coupled to the imageaperture.
 23. The system of claim 22, wherein the camera is intra-orallymounted.
 24. The system of claim 22, wherein the camera is mountedoutside of the oral cavity.
 25. A system to optically image a dentalstructure within an oral cavity, comprising: an intra-oral track adaptedto be inserted inside the oral cavity; a spray orifice moveably coupledto the track to coat the dental structure with a material; and at leastone image aperture movably coupled to the intra-oral track and adaptedto capture one or more images of the dental structure.
 26. A system tooptically image a dental structure within an oral cavity, comprising: anintra-oral track adapted to be inserted inside the oral cavity; apressurized air nozzle moveably coupled to the track to direct air atthe dental structure; a spray orifice moveably coupled to the track tocoat the dental structure with a material; and at least one imageaperture movably coupled to the intra-oral track and adapted to captureone or more images of the dental structure.
 27. A method for opticallyimaging a dental structure within an oral cavity, comprising: a) coatingthe dental structure with a substance to enhance the image quality; andb) capturing one or more images of the dental structure through at leastone image aperture, the image aperture movably coupled to the intra-oraltrack.
 28. A method for optically imaging a dental structure within anoral cavity, comprising: a) directing air at a tooth-gum interface ofthe dental structure through at least one air nozzle movably coupled toan intra-oral track; b) coating the dental structure with a substance toenhance the image quality; and c) capturing one or more images of thedental structure through at least one image aperture, the image aperturemovably coupled to the intra-oral track.